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FLOATING BRAKE ROTOR (DISC) KITS
J030912007-03-12
GENERAL
Kit Numbers
42155-07, 42156-07, 42158-07, 44700-03, 44703-03, 44706-03, 44709-03
Models
For model fitment information, please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only).
Additional Parts Required
Separate purchase and installation of additional parts or accessories may be required for proper installation of this kit on your model motorcycle. Please see the P&A Retail Catalog or the Parts and Accessories section of www.harley-davidson.com (English only) for a list of required parts or accessories for your model.
WARNING
Rider and passenger safety depend upon the correct installation of this kit. Use the appropriate service manual procedures. If the procedure is not within your capabilities or you do not have the correct tools, have a Harley-Davidson dealer perform the installation. Improper installation of this kit could result in death or serious injury. (00333b)
NOTE
This instruction sheet references Service Manual information. A Service Manual for your model motorcycle is required for this installation and is available from a Harley-Davidson Dealer.
WARNING
Brakes are a critical safety component. Contact a Harley-Davidson dealer for brake repair or replacement. Improperly serviced brakes can adversely affect brake performance, which could result in death or serious injury. (00054a)
Kit Contents
See Figure 1 and Table 1.
INSTALLATION
Preparation for Service
Models WITH maxi-fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, remove main fuse before proceeding. (00251b)
  1. Refer to the Service Manual and follow the instructions given to remove the maxi-fuse.
Models WITHOUT maxi-fuse:
WARNING
To prevent accidental vehicle start-up, which could cause death or serious injury, disconnect negative (-) battery cable before proceeding. (00048a)
  1. Refer to the Service Manual and follow the instructions given to remove the seat and disconnect the negative (black) battery cable from the negative (-) battery terminal. Retain all seat mounting hardware.
    2. NOTE
    For 2004 and later XL (Sportster®) models, the negative battery cable is most easily disconnected at the engine crankcase.
Removal and Disassembly
  1. Refer to FRONT WHEEL: REMOVAL or REAR WHEEL: REMOVAL in the Service Manual, and follow the instructions to remove the wheel from the motorcycle. Use a TORX® drive head to remove the screws retaining the currently installed brake disc to the wheel. The brake disc and screws can be discarded.
  2. Inspect the wheel bearings per the PRELIMINARY INSPECTION instructions in the appropriate WHEEL section. Follow the DISASSEMBLY and CLEANING AND INSPECTION instructions as necessary to properly service the wheel.
Reassembly and Installation
NOTICE
Do not re-use brake disc/rotor screws. Re-using these screws can result in torque loss and damage to brake components. (00319c)
  1. Refer to WHEEL: ASSEMBLY in the Service Manual, and follow the instructions to install the new brake disc to the wheel, using the new TORX screws from the kit. Complete the ASSEMBLY instructions as necessary to service the wheel.
  2. Refer to WHEEL: INSTALLATION in the Service Manual, and follow the instructions to re-install the wheel to the motorcycle.
Return to Service
1. Verify that the Ignition/Light Key Switch is turned to the OFF position.
2. Models WITH maxi-fuse: Refer to the Service Manual and follow the instructions given to re-install the maxi-fuse. Models WITHOUT maxi-fuse: Apply a light coat of petroleum jelly or corrosion retardant material to the negative battery terminal. Refer to the Service Manual and follow the instructions given to re-attach the negative battery cable.
3. Turn the Ignition/Light Key Switch to the ON position.
4. Pump the brake lever to verify operation of the brake lamp.
WARNING
After servicing brakes and before moving motorcycle, pump brakes to build brake system pressure. Insufficient pressure can adversely affect brake performance, which could result in death or serious injury. (00279a)
WARNING
After repairing the brake system, test brakes at low speed. If brakes are not operating properly, testing at high speeds can cause loss of control, which could result in death or serious injury. (00289a)
5. Test ride the motorcycle to verify the brakes are operating properly.
NOTE
If possible, avoid hard stops for the first 300 miles (483 km). Hard stops during the wear-in period will gall the brake discs.
SERVICE PARTS
Figure 1. Service Parts, Floating Brake Rotor (Disc) Kits
Table 1. Service Parts Table
Kit
Item
Description (Quantity)
Part Number
Front Brake Rotor Kit
42155-07, "Blade" (left)
42156-07, "Blade" (right)
44700-03, "Road Winder™" (left)
44703-03, "Road Winder" (right)
1
Brake rotor, front
Not sold separately
2
Screw, pan head, T-40 TORX®,
5/16-18 x 7/8 in. long, with lock patch (5)
3655A
Rear Brake Rotor Kit
42158-07, "Blade"
44706-03, "Road Winder" (right)
44709-03, "Road Winder" (left)
1
Brake rotor, rear
Not sold separately
2
Screw, pan head, T-45 TORX,
3/8-16 x one in. long, with lock patch (5)
43567-92